Fernco PS100 HDPE Penstocks Instruction Manual

: June 13, 2024
: Fernco

Table of Contents

Fernco PS100 HDPE Penstocks
Product Information
Product Usage Instructions
Operational
Maintenance
Product Specification
Standard Series Product Range
Accessories & Installation
Handling and Storage
- Procedure for Installing Chemical Anchor Attachments
General Information
Technical Support
Documents / Resources

Fernco PS100 HDPE Penstocks

Product Information

HDPE Penstocks from Fernco

Fernco’s HDPE Penstocks are designed to provide a high-strength, easy-to-install solution for controlling the flow of water and wastewater.
They are commonly used in various applications such as Waterways, Power Plants, Industrial Effluent Plants, Hydro Power, sewage/Wastewater Treatment Plants, Drainage, and Flood Control.
The penstocks are made from HDPE (High-Density Polyethylene), which offers several advantages over other materials. These include:

Operational Benefits: The penstocks are considerably lighter than alternatives, making them easier to install without the need for grout between the frame and wall.
Maintenance Benefits: The product requires minimal lubrication between the frame and the door, resulting in a longer product life. The range also has leakage rates that exceed the requirements of industry standards such as BS 7775 and DIN 19569-4 class 5.

Fernco Penstocks are fitted onto the civil structure from work or over an aperture in a wall. Each penstock comes with a BS Cap supplied.

Product Usage Instructions

Identify the required size of the penstock based on the total width and height measurements provided in the product specification.
Ensure that the pressure rating of the penstock meets the requirements of your application.
Choose the appropriate mounting set based on the weight specified in the product specification.
If additional component parts are needed for installation or customization, refer to the Accessories & Installation section.
Contact Fernco’s sales team at +44 (0) 1226 340 222 or sales@fernco.co.uk to place an order or inquire about specific product details.
For more convenience, consider using the Fernco App for iOS and Android to quickly find the right product.

Note: Proper installation and usage of the penstock are crucial for its effectiveness.
It is recommended to consult the complete user manual or contact Fernco for any additional guidance or support.

Contact Information:

Phone: +44 (0) 1226 340 222
Email:sales@fernco.co.uk
Website:www.fernco.co.uk
Lightweight range of wall-mounted penstocks
Easy and quick installation – no need for grout between frame and wall
Corrosion resistant
Robust and rigid construction
UV stable
Little to no maintenance is required
Manufactured to DIN. 19569-4 class 5
HDPE Penstocks from Fernco provide a high-strength, easy-to-install solution to control the flow of water and wastewater.
Penstocks, in their basic form, are permanent water gates that control the flow of water from one area to the next, which can be manually adjusted depending on the desired flow.
They are often used on Waterways, Power Plants, Industrial Effluent Plants, Hydro Power, Sewerage/Wastewater Treatment Plants, Drainage, and Flood Control.
With a core range manufactured from HDPE (High-Density Polyethylene), Fernco’s range offers considerable benefits over other materials including:

Operational

The range is considerably lighter than alternatives, resulting in easier installation with no grout required between frame and wall.

Maintenance

The product requires little lubrication between the frame and the door resulting in a longer life product. The range has leakage rates that are better than those required in both BS 7775 and DIN. 19569-4 class 5.
Fernco Penstocks, unlike valves, are fitted onto the civil structure from work or over an aperture in a wall.
All Fernco Penstocks come with a BS Cap supplied.

Product Specification

Fernco-PS100-HDPE-Penstocks-
FIG-2

Construction Materials

Standard Series Product Range

Product Code| Diameter (Ø)| A Total Width (mm)| B Total Height (mm)| Pressure (Mac)| Weight (kg)| Mounting Set|
---|---|---|---|---|---|---|---
PS100| 100| 242| 437| 6| 10.4| PSMS-01
PS150| 150| 294| 537| 6| 16| PSMS-01
PS200| 200| 342| 637| 6| 22| PSMS-01
PS250| 250| 394| 737| 6| 26| PSMS-01
PS300| 300| 442| 837| 6| 31| PSMS-01
Product Code| Diameter

(Ø)

| A

Total Width

(mm)

| B

Total Height

(mm)

| Pressure

(mac)

| Weight

(kg)

| Mounting Set|
PS400| 400| 670| 1150| 6| 55| PSMS-02|

Fernco-PS100-HDPE-Penstocks-FIG-4

Accessories & Installation

Additional Component Parts

Fernco-PS100-HDPE-Penstocks-FIG-5

Handling and Storage

Handling

The HDPE Penstock has to be moved horizontally with the Door plate facing up on a matching pallet size. It can then be lifted by means of suitable lifting slings and a lifting bar matching the width of the penstock if required.
Where chains or slings are used for handling purposes the frame should be protected using cloth sacking or similar material. Hooks are only to be used where eyebolts are fitted.

Storage

It is recommended to store the penstock horizontally, free of dust, dirt and moisture.

Installation Sequence

The installation of penstocks, avoiding distortion and consequent leakage, is not difficult providing these recommendations are followed.
Prior to commencing installation, check the civil work is correct to all appropriate drawings and that there are no obvious obstructions or undulations on the concrete surfaces. It will affect the seal of the penstock if the civil structure is not flat.
It is recommended that the mounting set is purchased with the penstock for ease of installation.

Wall mounting set components

Stainless Steel Threaded Studding
Chemical Anchor Capsules
Drill Adaptor
Stainless Steel Nuts, Washers

Marking the Chemical Anchor Bolts

With suitable lifting slings, lift the penstock up and adjust it to ensure it is vertical and level
Lower the penstock into the required aperture.
Check and adjust the penstock to the correct position. Ensure the invert of the pipe is flush with the invert of the frame.
Mark all the mounting holes.
- NOTE: On penstocks over 500mm in diameter, there are also holes above the penstock opening. These are accessed by fully closing the penstock.
Remove the penstock and attach the EPDM seal.

Placing the EPDM seal

Before placing the EPDM seal, ensure that the mounting face is clean and smooth.
Mark the mounting holes onto the seal with a white pencil, so that they correspond with the existing holes in the frame.
The seal is self-adhesive on one side. Cut the seal oversized, then remove the protection slip and fit the seal to the frame.
The seal should now be cut to length and squared so that the corners connect properly.
Glue the corners together by using a suitable glue. When not glued properly it can lead to leakage between the sealing face and the concrete wall.
Drill the previously marked holes in the seal.
Place the penstock back into position, ensuring not damage the EPDM seal.
Re-position the penstock, checking all levels and that the inverts are aligned.
Follow the applicable instructions for the chemical anchors to install the penstock.

Follow the instructions supplied by the manufacturer of the chemical anchors. The curing time should be considered precisely.

Procedure for Installing Chemical Anchor Attachments

Drill the Mounting hole in the required position to the correct depth and diameter.
Blow out the drilled hole using compressed air. (Warning: suitable eye protection to be worn)
Insert a chemical anchor capsule into each hole.
Attach a length of studding to the drill adaptor, then attach the adaptor to a rotary drill (NOTE: Do not use a hammer-action drill, as this will cause resin to escape from the hole).
Place the end of the threaded stud into the hole, then in one motion operate the drill at high speed, while pushing the stud through the anchor to the back of the hole. Once the back of the hole is reached, stop the drill to prevent resin escape.
Carefully remove the drill adaptor from the drill chuck, taking care not to move the stud.
Once the resin has sufficiently cured, remove the drill adaptor from the stud, however if the stud turns, leave the resin to cure further.
Replace the item to be mounted, then place a washer, a spring washer and a nut onto the stud and tighten by hand.
Once all required anchors have been installed and are fully cured, proceed to tighten the nuts evenly. The EPDM seal must be compressed evenly to ensure a good seal, however the frame must not be allowed to deform.

NOTE: If any of the threaded studs turn, leave them longer to cure.

Installation of the Non Rising Extension Spindle

Place the spindle extension with the support(s) on top of the top bridge.
Place the upper support 150 mm below the deck or top of the spindle extension. Divide the other supports evenly over the length of the spindle extension.
Mark the anchor holes of the supports in such a way that the spindle extension is parralel to the penstock and vertical.
Remove the spindle extension.
Follow instructions for mounting of chemical anchors (see p.5)
Replace the spindle extension and the brackets and fix these to the wall (place locking ring onto the spindle before placing the uppermost bracket)
Adjust the position of the brackets to ensure a proper alignment of the spindle extension.
Locate the spindle extension under the uppermost bracket and lock into position.

Operation Recommendations for HDPE Penstocks

Operation of the penstock is straightforward, providing the installation recommendations have been carried out correctly.

The seals on a penstock are specially designed to give the best degree of water tightness, assuming that the unit is installed correctly.
If excessive leakage occurs, the most likely explanations are:
- The frame has been distorted during installation.
- The door adjusters have been moved prior to, during, or after installation.
- There is debris between the door and the frame at the invert.
- The seals have been scored or damaged in some way.
- The operating equipment is out of alignment.
DO NOT use excessive force when opening or closing a penstock door, as damage could occur.

Maintenance Recommendations HDPE Penstocks

The penstock should give years of trouble-free operation, providing the following simple inspection procedures are adopted. THE FREQUENCY OF INSPECTION SHOULD BE BASED ON THE PARTICULAR REQUIREMENTS OF THE INSTALLATION.
The following parts require attention in particular and need to be cleaned if necessary:
Spindle block (dirt and wear)
Spindle (dirt and wear)
Spindle stop (present)
Sealing (dirt and wear)

NOTE: Do not grease any part of the penstock unless otherwise instructed. In an aggressive environment or in locations with large amounts of silt or debris, it is strongly recommended to increase the inspection/maintenance interval.

Clean the unit by hosing it down to remove any grit or debris.
Check for leakage between the frame and the concrete wall. Correct any faults that are found.
Check the tightness of the bolts and nuts.
Check there is no damage to the frame, door or seals.
When carrying out any maintenance work with the penstock door in the open position, ALWAYS ENSURE that the door is securely and independently supported from underneath.

General Information

Quality, Standards and Approvals

Fernco has been certified by the British Standards Institution (BSI) as a company of assessed capability, with a quality management system which meets the requirements of BS EN ISO 9001:2015
Fernco UK, part of a global group of companies, are the leaders in wastewater connection innovation; utilising the most advanced methods and techniques for precision-manufactured products, all of which comply with or exceed relevant British and European standards to ensure reliability and sustainability.

Environment

Fernco operate Environmental Management Systems which are certified to ISO 14001: 2015.

Supply

Fernco are proud members of the Builders Merchants Federation (BMF). All Fernco products are supplied through a national and global network of distribution and merchant partners. For stockist details, contact Fernco.

Technical Support

Fernco have a team of product experts on hand to support all customers with technical support and advice.
Contact Fernco Technical Department: Tel: +44 (0) 1226 344100
Email: technical@fernco.co.uk

Enquiries UK Sales: